Key Benefits of Converting from Wire Flame Spray to Thermach's Twin-Wire Arc Spray
- Dan Haas
- Nov 17
- 2 min read
Get your coating operation focused on performance, cost, and reliability!
A twin wire arc spray process is called arc spray, electric arc wire spray, or metallizing. It uses two conductive wires fed into a gun, where an electric arc melts them and compressed air atomizes the molten metal into a spray. This is distinct from flame spraying, which uses a combustion flame to melt the wire.
Why Upgrade from Wire Flame Spray to Thermach's Twin-Wire Arc Spray?
1. Higher Deposition Rates (this equals faster production!)
Twin-wire arc systems melt wire using an electric arc instead of a fuel/oxygen flame, resulting in:
Much higher spray rates
Faster buildup of thickness
Shorter job times and higher throughput
Production shops typically see 2–4x faster deposition depending on the material.
2. Lower Operating Costs
Arc spray eliminates fuel gases (acetylene, propane, etc.). Savings include:
No fuel gas purchase, storage, or regulation
Lower gas handling and safety costs
Less energy consumption overall
For many operations, this is one of the biggest ROI drivers.
3. Better Bond Strength
Arc-sprayed coatings generally achieve:
Higher bond strength than wire flame spray
Improved mechanical interlocking due to higher particle velocities
More reliable adhesion on shafts, rolls, and heavy-equipment components
This means stronger, longer-lasting repairs.
4. Denser, More Wear-Resistant Coatings
Compared to wire flame spray, twin-wire arc produces:
Lower oxide content
Higher coating density
Better wear and erosion resistance
Particularly beneficial for steel, bronze, and nickel-based wires.
5. Cooler Process — Less Heat Distortion
Arc spray transfers minimal heat into the workpiece:
Reduced risk of distortion
Ideal for thin-wall components
Supports tight tolerances
It’s considered one of the “coldest” thermal spray processes.
6. Material Flexibility
Twin-wire arc spray accommodates a wide range of wire materials:
Carbon and stainless steel
Bronze, copper, aluminum
Nickel-based alloys
Zinc and aluminum for corrosion protection
This makes it valuable for both repair and corrosion-control applications.
7. Consistent Automated Control
Modern arc systems can integrate:
Closed-loop current/voltage control
Automated feeders
Robotic motion systems
This leads to repeatable, production-grade quality.
8. Environmentally & Operationally Safer
Switching eliminates:
Open flame
Fuel gas cylinders
Combustion byproducts
This reduces hazards and simplifies facility compliance.
Remember, Thermach is not your competitor; your other options are. We don’t coat; we only supply thermal spray equipment and parts. You can proceed with confidence, knowing that our team is dedicated to creating a custom system that meets your exact specifications.
Manufacturer of Equipment & Parts for the Thermal Spray Industry. Backed by Reliable, Timely Service & Support.
Thermach manufactures thermal spray coating systems for the coating industry. We don't coat. We provide the equipment and parts necessary for you to run a successful coating operation. Our mission is to ensure your coating process is running smoothly with Thermach equipment.
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